[engine_work] I Forgot How Much I Missed It!

[DrSarty 90 1 Cars]

Hello all. This is being written even before I've driven my 205 again. The car in question is the white, Colin Satchell modified 205 formerly known as 'Evo II'; there is a topic in the Projects section.

 

In this new topic you will find:

• the rebirth of this car (basically building and putting a new engine in it)
  
• pictures of the engine with my home-made throttle body set-up
  
• a solution/alternative for a hard-to-find Mi16 part
  
• hopefully a happy result from mapping at Emerald and another chance to for me to use this car regularly
  

Welcome to 'Sarty Evo Redux'.

 

The former 2.2 (2187cc) thumper of an engine survived 3 years, but eventually - probably partly through my own neglect - had an issue with the piston rings on cyl 1. It got broken up and sent to various places, including some parts like the £700 forged pistons all going to the scrap metal merchant!

 

Financial and life circumstances interfered with putting the car back on the road (that used to look like this below), meaning it has languished in a Devon workshop, pining for a new power plant.

 

 

I've had (and still have), quite a few XU9J4 (Mi16 1.9 alloy block) engines as 'kits' ready to build up or finish off, and recently I've had a chance to use a professional and freshly rebuilt Mi lump sitting on an engine stand which just needed a head, gearbox, inlet and exahust.

 

Later today I'll post some pictures of how it's taken shape over the last few days, and nights. And this is the reason behind the topic title, as I went into the garage at 8pm on Monday night, and came out again at 3am the following morning!

 

It's this obsession and absorption in making engines and working on cars and stuff that I missed, with the looming promise of a very rapid and rewarding car at the end of it.

 

Here's to 205s and tinkering with mechanical things. Whoop!

Edited May 10, 2012 by DrSarty

[petert 586]

Glad to hear you're in the groove again.

[maturin23 10]

Welcome back matey.

 

I'm missing mine and it's only been with JackHerer for a week (sorting out some rust issues and other cosmetics (new bumpers/lights) including some pretty bad rot above the driver's door).

 

I take it this is the shell with Sandy's reworked rear suspension - are you planning on revising the spring rates and/or damping? Although it was only a brief blast I seem to recall it felt a little floaty over that stretch of undulating country lane.

[marksorrento205 80]

Nice to see you have the bug again Rich

[brumster 135 1 Cars]

Lord help us, he's back

 

Shouldn't this be a project thread?!

 

Welcome back chap...

[DrSarty 90 1 Cars]

Thanks for the welcoming (back) comments.

 

Ian - Yes, re your suspension query; it never was actually set up. It'll be getting corner weighted and stuff, and I've already discussed this with JackHerer, who incidentally provided the Mi16 gearbox going in the car.

 

Pics showing some engine build up once the head was on:

 

More detail on the ITBs:

 

I am happy to make another set for another forum member, already fitted with cleaned and tested Mi or GTI6 injectors for £425.

 

I've fitted a 6bar oil pump spring, and you can perhaps see the previously fitted (and improvised) pump baffle. It already has the chain guard. The extended pick up for the pump and windage tray will be fitted later, before I do any track days/hill climbs. It's an S16 (XU10J4) steel sump I believe.

 

Other details:

VAG alternator tensioner (I like them)

Alloy rear water housing 3-outlet

GTI6 injectors

Trumpets being finalised

Custom ITG JC50 air filter on its way

Oil breather catch tank bracket-mounted to side of head

Still some oil breather pipe simplification to follow

6mm heat insulating spacer between head and inlet runners

Stage II PeterT inlet cam (ground from inlet cam)

Stage I PeterT inlet cam used as exhaust (ground from exhaust cam) - these 2 cam choices mean OE 4 and 2 pulleys can be used

Lightweight Miles alloy crank pulley

PSA twin coil wasted spark coil pack

 

Perhaps this should or will be another project topic, but that's a mod choice to move it I think, as you can't start new topics in that forum.

Edited May 10, 2012 by DrSarty

[Chris_Mi 6]

Welcome back Rich!

I will be watching this thread with interest!

[allye 530 3 Cars]

Perhaps this should or will be another project topic, but that's a mod choice to move it I think, as you can't start new topics in that forum.

 

You can in project works starters

 

I look forward to having the much talk'd about Mr.Sarty about as you were before my time Look forward to the progress.

[Mad Scientist 106]

Good to have you back Rich. You're original engine build was my inspiration. In fact, that probably means you've cost me a fortune!

 

Will be watching this one.

[SAW 1]

Cracking looking 205 you got there.

[S@m 156]

Looking real good! Just one question, which xu engine did the breathers come from (one of the xu7's i think)? I'm tempted to copy that set up.

 

Sam

[M@tt 77]

he's back with his 40% warn, the forums bad boy!

[DrSarty 90 1 Cars]

which xu engine did the breathers come from (one of the xu7's i think)? I'm tempted to copy that set up.

 

Yep and go for it. It seems to work really well, as it's tidy and simple.

 

The S16/iron block I had previously had an outlet needing plumbing in to the right of the block needing separate hoses; but the alloy block is far simpler when you use the Y-piece as I have going into the filler stack. This is why currently my filler stack has 2 unused outlets which will be either joined by a shorted U bend or filled with chem metal.

 

It seems a tidy solution.

 

Also, it is practically impossible to get replacement Mi16 spark plug hole oil seals as per the below picture (item 3). I've found that bath plugs work perfectly with a 30mm hole put through them. At less than a pound each that's a workable solution too.

 

Edited May 11, 2012 by DrSarty

[damien 22 1 Cars]

hi ya rich, sarah asks "how is nico?" (sp?)

[welshpug 1,657]

What were the throttle bodies originally found on?

 

Nice to see you back fiddling Rich

 

p.s the seal is part 8 on this picture -

 

Edited May 11, 2012 by welshpug

[DrSarty 90 1 Cars]

Thanks Meirion; you're right about the seal. The seal I showed is still available, and there are 3 for the central cam cover bolt holes. Your diagram shows the seal I mean of which there are 4.

 

The ITBs come in 3's on a Triumph motorbike. Well made, simple to turn into a bank of 4 as already suitably spaced, with decent throttle quadrant, TPSensor, ready for car-sized fuel injectors. 43mm internal bore, round to lozenge.

 

Nico is fine Damien. 6.5 now; decent at football but confused about which team he supports.

Edited May 11, 2012 by DrSarty

[GLPoomobile 958]

Have you PM'd Steve@Cornwall yet about getting the infamous wheels back?

[SurGie 54]

he's back with his 40% warn, the forums bad boy!

 

Yep, looks like my rein on that one is now over

 

Welcome back DrSarty, forums changed a fair bit recently

 

I thought you had sold evo, did it not happen or did you buy her back ?

[DrSarty 90 1 Cars]

Only sold the engine, ECU, gearbox (with TranX diff) and exhaust.

 

Car's been dried stored, and all loom and ancilliaries are there waiting for the lump to be dropped in.

 

Today went to breaker's (Newbridge/Nr Edinburgh) today to find, remove (!!!) and buy 2 x 106/Saxo coilpacks. Took GLPoomobile with me; it was his first ever trip to a breaker's yard! Those torx bolts are small and a barsteward to undo without rounding them. Succeeded, and now have 1 plus a spare.

 

K6 ECU delivered today, and ITG JC50 air filter with backplate are enroute, customised with the outer foam rotated so the ITG logo reads the right way up.

[harryskid 193]

Great stuff !

[miamichris 9]

Good to see you back Sarty, and looking forward to seeing this come together!

[Mad Scientist 106]

My itg logo is upside down! Fail!

[DrSarty 90 1 Cars]

Spoke with Anthony today, who'll hopefully be confirming later that the below and attached are correct. This is regarding wiring for the Saxo/106 coilpack.

 

{Viewing from front of car}

 

ENGINE (Cyls)

(4) (3) (2) (1) >>> Flywheel

 

COILPACK (HT lead posts)

*Multi connector pin order 4-3-2-1*

(4) (1)

(3) (2)

 

*Pins for coilpack used as follows:

1 = Trigger from ECU cyls 1+4

2 = Trigger from ECU cyls 2+3

3 = 12v power from double-relay/fuse/shunt box (ideally should be fused)

4 = Suppressed ground via 'condensor' which bolts to earth via condensor tab

 

Hope this is correct. Had to trawl some Saxo forums to assemble the information, which wasn't a pleasant experience (nuff said mate innit)!

Saxo and 106 Haynes 134.pdf

Edited May 14, 2012 by DrSarty

[welshpug 1,657]

looks good, same as my Motronic MP3.1 arrangement

[GLPoomobile 958]

Had to trawl some Saxo forums to assemble the information, which wasn't a pleasant experience (nuff said mate innit)!

 

Oh dear God! Have you recovered yet? I'm surprised you didn't call me after, to vent off about how society is completely f***ed after only spending a few minutes within those circles! Or maybe you have a little affinity with them (phat tunez pumped at volume through far too much audio equipment)